Sr. FMEA Moderator
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Job Description
As Sr. FMEA Moderator you lead Design and Process FMEAs from product development to series production. You guide cross-functional teams through the AIAG-VDA method, make sure every risk is understood, prioritized and controlled - in the design, on the shop floor and in the Control Plan - and coach other engineers to become moderators.
Ideal for Quality, Advanced Quality (APQP) or Process Engineers who already facilitate DFMEA/PFMEA (AMEF) workshops.
The role reports to the Team Leader Quality, supports projects and plants in several regions (remote and on site), and the work model is hybrid (3 days in office, 2 remote).
Main Responsibilities
• Plan, moderate and document DFMEA (system, software, hardware, mechanics) and PFMEA (manufacturing and logistics) according to the AIAG-VDA FMEA Handbook, using APIS IQ-RM PRO.
• Guide teams step by step through the 7 AIAG-VDA steps: block/boundary and P-diagrams, structure trees, function and failure nets, risk analysis with Action Priority (AP) and optimization.
• Ensure the cascade from requirements to DFMEA, process flow, PFMEA, Control Plan and work instructions, including the special characteristics list.
• Support PFMEA in production: line walks, process flow analysis, linking prevention and detection controls with the Control Plan, and managing quality concerns (QC) through the FMEA.
• Drive launch readiness of new lines and changes: PFMEA risk analysis before dry runs and Run@Rate, and verification of error-proofing (poka-yoke) devices with red rabbits.
• Feed 8D results, lessons learned and Yokoten back into DFMEA/PFMEA; plan and lead Reverse PFMEA and periodic reviews of generic FMEAs.
• Confirm the methodical and formal correctness before release; lead FMEA reviews and line walks, the approval workflow and the documentation in the FMEA document management system.
• Track actions to closure, verify their effectiveness and escalate delays; report FMEA status, KPIs and maturity to project and plant management.
• Lead management and customer FMEA reviews and support audits, ensuring compliance with customer-specific requirements (CSR).
• Coach engineers and moderator candidates (tandem moderation, feedback) and deliver FMEA workshops and awareness trainings for project and production teams.
• Improve FMEA templates, generic FMEAs and digital/AI-assisted FMEA checks.
Requirements
Function: Quality Assurance
Experience Level: Mid-Senior Level